Polyaxial screw assembly

ABSTRACT

A polyaxial screw assembly includes a pedicle screw, a coupling, an insert, and a housing. The pedicle screw includes a shank having a helical thread formed thereon and a head at one end. The coupling is positioned on top the pedicle screw and releasably engages portions of the head. The coupling and pedicle screw are positioned within a distal portion of the housing. The pedicle screw is slid through an opening in the insert and the insert is thread into the distal portion of the housing to retain the coupling and the pedicle screw within the housing. The pedicle screw is rotatable and pivotable relative to the housing. Compressing the coupling within the housing locks the pedicle screw in a desired orientation.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 12/739,506, filed on Apr. 23, 2010, now U.S. Pat. No. 8,403,971, which is a National Stage Application of International Application No. PCT/US/2008/080668, filed on Oct. 22, 2008 and published as WO2009/055400, which claims priority to, and the benefit of, U.S. Provisional Patent Application No. 61/000,072, filed on Oct. 23, 2007, the entire contents of each these prior applications hereby incorporated by reference.

BACKGROUND

1. Technical Field

The present disclosure relates to pedicle screws and, more particularly, to a polyaxial screw assembly.

2. Background of Related Art

The adult human spinal column has more than twenty discrete bones sequentially coupled to one another by a tri joint complex consisting of an anterior disc and the two posterior facet joints. The anterior discs of adjacent bones are cushioned by cartilage spacers referred to as intervertebral discs. The bones of the spinal column are anatomically categorized as being members of one of four classifications: cervical, thoracic, lumbar, or sacral. The cervical portion of the spine is the top of the spine and includes the first seven vertebrae from the base of the skull. The next twelve bones are the thoracic vertebrae. Thereafter, the next five bones form the lumbar vertebrae. Connecting to the lumbar, the sacral bones are at the base of the spine and include the coccyx.

The spine is a highly flexible structure, capable of a high degree of curvature and twist in nearly every direction. Genetic or developmental irregularities, trauma, chronic stress, tumors, and disease, however, can result in spinal pathologies. Spinal pathologies either limit the range of motion of the spine or threaten the critical elements of the nervous system housed within the spinal column. There are many systems that immobilize the spine by implanting artificial assemblies in or on the spinal column. The implantable assemblies are classified as anterior, posterior, or lateral implants. As the name of the classification suggests, lateral and anterior implants are coupled to the anterior portion of the spine. Posterior implants generally comprise rod assemblies that are attached to the spinal column by either 1) hooks coupled to the lamina or the transverse processes, or 2) by screws inserted through the pedicles.

The screws are implanted through the posterior lateral surfaces of the laminae, through the pedicles, and into their respective vertebral bodies. The screws have upper portions that are coupling elements for receiving and securing an elongate rod. The elongate rod extends along the axis of the spine and is coupled to the screws via the coupling elements. The rigidity of the elongated rod aligns the spine in a more desired shape.

Inserting screws along a misaligned curvature of the spine, while exactly positioning the coupling elements, can be difficult. The coupling elements must be placed in a way that a rod can be passed therethrough without damaging the screws. As a result, the surgeon must be careful when trying to properly align fixed screws, which increases the operating time and leads to an increased probability of a complication.

The art contains screws that permit a limited amount of freedom with respect to angulation of the coupling element. These assemblies, however, are generally complex, unreliable, and lack durability.

SUMMARY

A polyaxial screw assembly is presently disclosed. The polyaxial screw assembly includes a pedicle screw, a coupling, a housing, and an insert. The pedicle screw has a head having a recess and a plurality of gaps. The coupling has a plurality of knobs that mate with the plurality of gaps and the lower surface of the coupling mates with the recess in the head of the pedicle screw. The housing has a passageway that forms a longitudinal axis through the housing. The passageway narrows at a point between a distal opening and a proximal opening. The distal portion of the passageway is partially threaded. The insert is configured to be slid over the shank of the pedicle screw and thread into the distal opening of the housing. The insert has a threaded outer diameter that mates with the threaded distal portion of the housing and an opening extending therethrough. The diameter of the opening of the insert is dimensioned to be less than the outer diameter of the bead and greater than the shank of the pedicle screw. As a result, the insert sandwiches the pedicle screw and coupling within the housing.

Threading the insert into the bottom of the housing joins the pedicle screw and coupling arrangement to the housing, thereby forming the polyaxial screw assembly. As assembled, the pedicle screw is rotatable and pivotable in the housing.

A proximal portion of the housing is shaped to form a U-shaped saddle. Placing a rod member in the saddle of the housing acts to compress the head of the pedicle screw against an inner surface of the housing, thereby securing the pedicle screw in a desired orientation. A locking member or setscrew is then threaded into the top of the housing for securing the rod member in position with respect to the housing. Each part of the polyaxial screw assembly is made of a biocompatible material.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the presently disclosed polyaxial screw assembly are described herein with reference to the accompanying drawings, wherein:

FIG. 1A is a perspective view of a polyaxial screw assembly according to the present disclosure;

FIG. 1B is an exploded front view, with parts separated, of the polyaxial screw assembly of FIG. 1A;

FIG. 2A is a front view of a housing;

FIG. 2B is a side cross-sectional view, taken along section line A-A, of the housing of FIG. 2A;

FIG. 3 is a bottom perspective view of an insert;

FIG. 4 is a perspective view of a coupling;

FIG. 5 is a perspective view of a pedicle screw;

FIG. 6 is an exploded front view, with parts separated, of a polyaxial screw assembly in accordance with another embodiment of the present disclosure;

FIG. 7 is an exploded front view, with parts separated, of a polyaxial screw assembly in accordance with still another embodiment of the present disclosure; and

FIG. 8 is a perspective view of the coupling, the pedicle screw, and three connectors in accordance with the embodiment of FIG. 7.

Other features and advantages of the present disclosure will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Embodiments of the presently disclosed polyaxial screw assembly will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. In the drawings and in the description which follows, the term “proximal”, as is traditional, will refer to the end of the polyaxial screw assembly which is closest to the operator while the term “distal” will refer to the end of the polyaxial screw assembly which is furthest from the operator.

Referring initially to FIGS. 1A and 1B, in which like reference numerals identify similar or identical elements, a polyaxial screw assembly is generally designated as 100. The polyaxial screw assembly 100 includes a pedicle screw 10, a coupling 30, an insert 50, and a housing 70. The steps of assembling the polyaxial screw assembly 100 include positioning the coupling 30 on top of the pedicle screw 10 and then the housing 70 is positioned over the coupling 30 and the pedicle screw. Then the insert 50 is passed over the distal end of the pedicle screw 10 and along the shaft towards the bottom of the housing 70. The insert 50 is then screwed into the housing 70 to hold the polyaxial screw assembly 100 together. The specific arrangements and interconnections of the various components will be described in further detail hereinafter.

Turning now to FIGS. 2A and 2B, the housing 70 will be described in additional detail. The housing 70 includes an annular body portion 72 having an opening therethrough with a pair of upstanding fingers 74. A U-shaped saddle 76 is defined between the fingers 74 and is configured for receiving a rod member (not shown). The body portion includes a generally helical thread 73 that is located in a lower section of the body portion 72 and is adapted for threadably engaging a corresponding thread 56 of the insert 50, as will be described in detail hereinafter. Each of the fingers 74 includes a portion of a generally helical thread 75 formed on the inner surface of the housing. The thread 75 is configured for threadably engaging a corresponding thread on a locking element (not shown). The locking element may be a setscrew or another threaded component, as is known in the art. The opening at the bottom of the housing 70 is capable of receiving the coupling 30 and the pedicle screw 10 without being able to completely pass therethrough.

As seen in FIG. 4, the coupling 30 has a generally annular body 32 with a plurality of outwardly extending knobs 36. In the illustrated embodiment, four knobs 36 are shown and each knob 36 is offset 90° from the adjacent knobs 36. It is envisioned that the knobs extend from the screw head and the annular body of the coupling has recesses to accept the knobs. An annular flange 34 is disposed at one end of the coupling 30. The flange 34 has an outer diameter that is greater than the outer diameter of the body 32. Additionally, a recess 38 is formed in the body 32 of the coupling 30. The recess 38 is configured and adapted for releasable engagement with a driving tool (not shown), as is known in the art. Although the recess 38 is illustrated with a six-pointed star pattern, other suitable configurations are contemplated. A tapered outer surface 33 is located about the distal end of the coupling 30.

Turning now to FIG. 5, the pedicle screw 10 will be discussed in detail. The pedicle screw 10 includes a shank 16 having a helical thread 14 formed thereon. A cutting portion 12 is formed at a distal end of the pedicle screw 10. A head 18 is located at a proximal end of the pedicle screw 10 and includes a plurality of segments 18 a. The segments 18 a are arranged in a circular configuration about the head 18. A gap 17 exists between each of the segments 18 a and is adapted for releasably receiving the plurality of knobs 36 of the coupling 30 (FIG. 4). A recess 20 is defined between the segments 18 a in the center of the head 18. The recess 20 has a tapered inner surface for receiving the body 32 of the coupling 30 (FIG. 4). When the coupling 30 is located in the recess 20, each of the knobs 36 are positioned within one of the corresponding gaps 17. Thus, the coupling 30 and the pedicle screw 10 are rotatably coupled such that rotation of the coupling 30 causes a corresponding rotation of the pedicle screw 10.

As seen in FIG. 3, the insert 50 is an annular ring 52 having an opening 54 extending therethrough. The opening 54 has a diameter that is greater than the shank 16 of the pedicle screw 10 and is smaller than the head 18 of the pedicle screw 10. A generally helical thread 56 is located on the outer surface of the annular ring 52. The thread 56 mates with the thread 75 of the housing 70 (see FIG. 2B).

Referring to FIGS. 1A-5, assembly and usage of the polyaxial screw assembly 100 will now be discussed in detail. Initially, the coupling 30 is seated within the top of the pedicle screw 10, such that each of the knobs 36 is interlocked with a corresponding gap 17 and the outer diameter of the coupling body 32 pivotably mates with the inner diameter of the pedicle screw recess 20. As a result, the coupling 30 is slidably received in the recess 20. The tapered outer surface 33 mates with the tapered inner surface of the recess 20 and allows the coupling 30 to be seated within the recess 20.

As previously discussed, when the coupling 30 is seated in the recess 20 of the pedicle screw 10, rotation of the coupling 30 causes a corresponding rotation of the pedicle screw 10, thereby allowing the pedicle screw 10 to be inserted and removed from a target location. The interaction of coupling 30 and recess 20 in screw 10 permits the screw to be driven in response to a driver tool which engages the coupling, even if the screw is disposed at an angle relative to the coupling. Thus, the screw shaft and driving tool can be out of alignment during insertion of the screw into bone.

The coupling 30 and the pedicle screw 10 are inserted into the housing 70. The distal opening in the housing 70 has a greater diameter than the outer diameters of either the head 18 or the coupling 30. The insert 50 is slid over the shank 16 of the pedicle screw 10 and threaded into the bottom of the housing 70. The opening 54 of the insert 50 has a diameter that is less than that of the head 18 of the pedicle screw 10, thereby inhibiting the pedicle screw 10 from passing through the opening 54 of the insert 50. By threading the insert 50 into the bottom of the housing 70, the pedicle screw 10 and the coupling 30 are retained in the housing and form the assembled polyaxial screw assembly 100. The pedicle screw 10 is rotatable and pivotable in relation to the housing 70.

After the polyaxial screw assembly 100 is positioned at a desired location in a patient, a rod member (not shown) is placed in the saddle 76 and is retained in the housing 70 using a locking screw (not shown). As the locking screw is tightened against the rod member, the rod member presses against the coupling 30, thereby pressing the head 18 of the pedicle screw 10 against the inner surfaces of the insert 50 and securing the pedicle screw 10 in position (i.e. locks the screw in place).

Polyaxial screw assembly 100 may be composed of a range of biocompatible materials including, but not limited to, titanium, titanium alloys, stainless steel, cobalt chrome and cobalt chrome alloys, ultra high molecular weight polyethylene, PEEK (polyetheretherketone), and other polymers such as polycarbonate urethane. A variety of manufacturing techniques may be employed to produce polyaxial screw assembly 100.

In another embodiment, shown in FIG. 6, polyaxial screw assembly 200 includes a pedicle screw 110, a coupling 130, an insert 50, and a housing 70. The insert 50 and the housing 70 are similar to those of polyaxial screw assembly 100. Pedicle screw 110 is similar to pedicle screw 10, except that pedicle screw 110 has six gaps 117 placed an equal distance about a recess 120. Coupling 130 is similar to coupling 30, except that coupling 130 has six knobs 136 placed an equal distance about the tapered outer surface 133. The six knobs 136 of the coupling 130 align with the six slots 117 of the pedicle screw 110. The tapered outer surface 133 and recess 120 slidably interface. It is envisioned that other numbers of knobs and slots may be utilized.

In still another embodiment, shown in FIGS. 7 and 8, polyaxial screw assembly 300 includes a pedicle screw 210, a coupling 230, an insert 50, a housing 70, and three connectors 280. The insert 50 and the housing 70 are similar to those of polyaxial screw assembly 100. Pedicle screw 210 is similar to pedicle screw 10, except that pedicle screw 210 does not have gaps 17. Pedicle screw 210 has three slots 217 placed an equal distance about a recess 220. Coupling 230 is similar to coupling 30, except that coupling 230 does not have knobs 36. Coupling 230 has three slots 236 placed an equal distance about the tapered outer surface 233. The slots 236 of the coupling 230 match with slots 217 of the pedicle screw. As shown in FIG. 8, three generally spherical load transferring connectors 280 are sized to fit into slots 217 and slots 236. The tapered outer surface 233 and recess 220 are allowed to slidably interface.

It will be understood that various modifications may be made to the embodiments of the presently disclosed polyaxial screw assembly. By way of example only, the insert could be welded to the housing instead of or in addition to engaging the housing by a threaded engagement. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure. 

What is claimed is:
 1. A polyaxial screw assembly comprising: a screw having a shank and a head, the head defining a central recess and including a plurality of spaced-apart segments disposed about the central recess, the plurality of spaced-apart segments defining a plurality of gaps therebetween; a coupling having a proximal flange and a body extending distally from the proximal flange, the body configured for seating within the central recess of the head of the screw with the proximal flange disposed proximally of the head of the screw; the body including a plurality of knobs extending radially outwardly therefrom, each of the knobs configured for positioning within one of the gaps defined between the spaced-apart segments of the head of the screw when the body is seated within the central recess; a housing defining a passageway therethrough including a distal portion and a proximal portion, the distal portion of the passageway configured to receive the coupling and the screw head; and an insert having an opening configured for positioning about the screw shank adjacent the screw head, the insert configured to engage the housing within the distal portion of the passageway of the housing to retain the screw head and the coupling within the housing between the housing and the insert.
 2. The polyaxial screw assembly of claim 1, wherein the housing is configured to releasably receive an orthopedic rod in the proximal portion of the passageway.
 3. The polyaxial screw assembly according to claim 2, wherein the housing forms a U-shaped saddle about the proximal portion of the passageway, the U-shaped saddle configured to releasably receive the orthopedic rod.
 4. The polyaxial screw assembly according to claim 3, further comprising a set screw releasably engagable within the proximal portion of the passageway of the housing to retain the orthopedic rod within the U-shaped saddle.
 5. The polyaxial screw assembly according to claim 1, wherein the distal portion of the passageway defines a diameter greater than a diameter of the head of the screw and greater than a diameter of the coupling, and wherein the proximal portion of the passageway defines a diameter smaller than the diameter of the head of the screw and smaller than the diameter of the coupling.
 6. The polyaxial screw assembly according to claim 1, wherein the opening of the insert defines a diameter greater than a diameter of the shank of the screw and smaller than a diameter of the head of the screw.
 7. The polyaxial screw assembly according to claim 1, wherein the housing defines threading on an inner surface thereof adjacent the distal portion of the passageway and wherein the insert defines threading on an exterior surface thereof, the threading of the insert configured to threadingly engage the threading of the housing to retain the screw head and the coupling within the housing between the housing and the insert.
 8. The polyaxial screw assembly according to claim 1, wherein the screw is movable relative to the housing a predetermined distance along a longitudinal axis of the housing when retained within the housing.
 9. The polyaxial screw assembly according to claim 8, wherein the screw is pivotable relative to the housing off the longitudinal axis at a predetermined angle.
 10. The polyaxial screw assembly according to claim 1, wherein the body of the coupling and the central recess of the head of the screw define complementary configurations to facilitate pivotal motion of the screw with respect to the coupling.
 11. The polyaxial screw assembly according to claim 1, wherein the coupling defines a tool-engaging recess configured to releasably receive a driving tool.
 12. A method, comprising providing a polyaxial screw assembly, including: a screw having a shank and a head, the head defining a central recess and including a plurality of spaced-apart segments disposed about the central recess, the plurality of spaced-apart segments defining a plurality of gaps therebetween; a coupling having a proximal flange and a body extending distally from the proximal flange, the body including a plurality of knobs extending radially outwardly therefrom; a housing defining a passageway therethrough including a distal portion and a proximal portion; and an insert having an opening extending therethrough; seating the body of the coupling within the central recess of the head of the screw such that the proximal flange of the coupling is disposed proximally of the head of the screw and such that each of the knobs is positioned within one of the gaps defined between the spaced-apart segments of the head of the screw; inserting the coupling and screw proximally into the distal portion of the passageway of the housing; advancing the insert proximally over the shank of the screw and into the distal portion of the passageway of the housing; and engaging the insert to the housing within the distal portion of the passageway to retain the screw head and the coupling within the housing between the housing and the insert.
 13. The method according to claim 12, further comprising inserting an orthopedic rod into the proximal portion of the passageway of the housing.
 14. The method according to claim 13, further comprising engaging a set screw within the proximal portion of the passageway of the housing to retain the orthopedic rod within the proximal portion of the passageway of the housing.
 15. The method according to claim 12, wherein engaging the insert to the housing within the distal portion of the passageway includes threadingly engaging the insert within the housing.
 16. The method according to claim 12, further comprising: engaging a driving tool with the coupling; and operating the driving tool to rotate the coupling, thereby rotating the screw to drive the screw into bone.
 17. The method according to claim 16, wherein the screw is angled relative to the driving tool during operation of the driving tool. 